Multiple compartment container assembly with suspended tray

ABSTRACT

A multiple compartment container assembly for containing at least two articles arranged one above the other. The assembly includes a carton defining a first, lower compartment and a tray suspended within carton, wherein the tray defines a second, upper compartment. The tray may be provided with tabs extending therefrom suitable for removable engagement with corresponding notches defined in the carton. The tray&#39;s tabs may each include one or more forwardly or rearwardly extending projections for engaging portions of the carton adjacent the carton&#39;s notches in order to ensure the tray is held in a suspended position within the carton. The carton&#39;s notches may each include one or more forwardly or rearwardly extending projections extending therein for retaining the tray&#39;s tabs and preventing the tabs from becoming inadvertently upwardly disengaged from the notches. It will be appreciated that the notches&#39; projections may be deflected in order to disengage the tray&#39;s tabs.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 61/798,701, filed on Mar. 15, 2013, to Ronald D. Robertson entitled “Multiple Compartment Package Assembly,” currently pending, the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Paperboard cartons are widely used in the fast food and quick serve restaurant industries to dispense food. Often, one carton is provided for holding an entrée, such as a burger or sandwich, and second carton is provided for holding a side dish, such as fries or onion rings. The two cartons are typically not readily stackable and, therefore, must be carried on a tray or otherwise require the consumer to carry one carton in each hand thereby tying up both of the consumer's hands.

Other restaurant menu options sometimes consist of two or more food items that are intended to be combined prior to consumption. Examples include the brownie and ice cream of a brown al a mode or the granola, fruit and yogurt of a parfait. Plastic parfait cups having an insert for containing granola and fruit are known in the art. However, these plastic cups are not generally biodegradable thereby resulting in adverse environmental impacts if they are not recycled.

Accordingly, a need exists for a container assembly comprising multiple compartments wherein multiple food items may be carried separately in a single container assembly until consumption. A need also exists for a multiple compartment container assembly that is readily recyclable or compostable upon disposal.

SUMMARY OF THE INVENTION

One embodiment of the present invention is directed to a multiple compartment container assembly for containing at least two generally articles arranged one above the other. The container assembly includes a carton and tray, where the tray is at least partially disposed within the carton. A first compartment is defined within a lower region of the carton and a second compartment is defined within the tray. One aspect of the present invention involves the means by which the tray is suspended within the interior of the carton.

The carton can be constructed of a bottom panel and a sidewall consisting of a front panel, rear panel, first end panel and second end panel extending generally upwardly from the bottom panel. In one embodiment, the carton includes a first notch defined proximate an upper or distal edge of the first end panel and a generally opposing second notch defined proximate an upper or distal edge of the second end panel.

The tray can be constructed of a bottom panel and a sidewall consisting of a front panel, rear panel, first end panel and second end panel extending generally upwardly from the bottom panel. In one embodiment, the tray includes a first tab extending from the tray's first end panel and a generally opposing second tab extending from the tray's second end panel. The tray's tabs may be adapted for selective engagement with the carton's notches for suspending the tray within the interior of the carton.

The tray's tabs may each include one or more holding projections that engage portions of the carton's end panels adjacent the carton's notches in order to ensure the tray is held in a suspended position within the carton. In one embodiment, the tabs each include a forwardly extending projection and a generally opposing rearwardly extending projection.

The carton's notches may each include an open upper end adapted for receiving the tray's tabs therethrough. The notches can further include one or more retaining projections extending therein for retaining the tray's tabs and preventing them from becoming inadvertently upwardly disengaged from the notches. In one embodiment, the notches each include a rearwardly extending projection and a forwardly extending projection that protrude into the notches. It will be appreciated that when deflected by a user, the notches' projections can allow the tabs to become upwardly disengaged from the notches.

It is a further object of the present invention to provide a foldable blank for forming the carton and a foldable blank for forming the tray. The blanks may each be die cut from a larger sheet or roll of paperboard material. The blanks can include score lines and/or fold lines to facilitate formation of the carton and tray in a folding process.

Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

FIG. 1 is an exploded top perspective view of a multiple compartment container assembly constructed in accordance with one embodiment of the present invention;

FIG. 2 is a top perspective view of a multiple compartment container assembly constructed in accordance with one embodiment of the present invention illustrating the tray suspended within an upper region the carton;

FIG. 3 is a top perspective view of a multiple compartment container assembly constructed in accordance with one embodiment of the present invention illustrating the carton lid in a closed position;

FIG. 4 is a plan view of a blank from which a carton of the multiple compartment container assembly may be formed in accordance with one embodiment of the present invention; and

FIG. 5 is a plan view of a blank from which a tray of the multiple compartment container assembly may be formed in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures.

The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

Referring to the figures, one embodiment of the present invention is directed to a container assembly 10 for containing a plurality of articles arranged generally one above the other. The container assembly 10 may define multiple compartments and can include a carton 12 and a tray 14 that may be suspended, hung or otherwise located within an upper region of the carton 12.

The carton 12 and tray 14 may each be constructed of paperboard, laminated paperboard, cardboard, polymers, thermoplastic materials, molded pulp fiber, laminated molded pulp fiber or any other suitable material now known or hereafter developed. The carton 12 and tray 14 may be coated on their interior and/or exterior surfaces with a waterproof or water-resistant material such as polyethylene, polypropylene or polyester. Other types of waterproof, water-resistant or heat-sealable coatings that are now known or hereafter developed may also be used. Various methods of applying the coating are well known in the art. Exposed edges of the carton 12 and tray 14 can be sealed to prevent the migration of liquids. The carton 12 and tray 14 may be constructed as being generally leak-proof and beads of adhesive or sealant may be applied at their seams. The exterior surfaces of the carton 12 and tray 14 may be suitable for having advertising, logos and other graphics printed thereon.

As illustrated, the carton 12 comprises five primary panels including a bottom panel 16 and a front panel 18, rear panel 20 and end panels 22 and 24 that are hingedly connected to the bottom panel 16 by score lines or fold lines 26, 28, 30 and 32, respectively. When the carton 12 is formed, the panels 18, 20, 22 and 24 extend generally upwardly from the bottom panel 16 to form a peripheral sidewall defining an interior of the carton 12.

The carton 12 optionally includes a reclosure means in the form of a cover panel 34 hingedly connected, for example, to a top end of the rear panel 20 via a fold line 36. The cover panel 34 may be selectively moved between open and closed positions. Alternatively, the carton 12 may include a cover or lid (not shown) that may set thereon in a covering orientation.

The carton 12 may further include flaps 40, 42, 44 and 46 extending from any of the front, rear and end panels 18, 20, 22 and 24 configured for securement to an adjacent panel. As shown, the flaps 40, 42, 44 and 46 extend from and are hingedly connected to side edges of the front and rear panels 18 and 20 by score lines or fold lines 48, 50, 52 and 54, respectively. As demonstrated in FIGS. 1-3, the flaps 40, 42, 44 and 46 are affixed to the end panels 22 and 24 when the carton 12 is formed. Securement of the flaps 40, 42, 44 and 46 can be achieved by adhesive, sonic welding, heat-sealable materials, sealant or the like.

In one embodiment, the front panel 18 includes a locking tab or latch 56 protruding from a top edge 58 thereof. In the same embodiment, the cover panel 34 includes one or more corresponding slits or slots 60 defined therein and configured for engagement with the locking tab 56 of the front panel 18 for maintaining the cover panel 34 in a closed orientation. However, it will be appreciated that the locking tab 56 may extend from the cover panel 34 and the slits or slots 60 may be formed in the front panel 18. It will also be appreciated that other locking or latching configurations may instead be implemented.

As depicted, the tray 14 comprises five primary panels including a bottom panel 62 and a front panel 64, rear panel 66 and end panels 68 and 70 that are hingedly connected to the bottom panel 62 by score lines or fold lines 72, 74, 76 and 78, respectively. Optionally, the tray 14 optionally includes a cover or lid (not shown), which can be hingedly attached to one of the front, rear or end panels 64, 66, 68 or 70 or may otherwise be set on the tray 14 in a covering fashion. The tray 14 may further include flaps 80, 82, 84 and 86 extending from any of the front, rear or end panels 64, 66, 68 or 70 configured for securement to an adjacent panel. As shown, the flaps 80, 82, 84 and 86 extend from and are hingedly connected to side edges of the front and rear panels 64 and 66 by score lines or fold lines 88, 90, 92 and 94, respectively. As demonstrated in FIGS. 1 and 2, the flaps 80, 82, 84 and 86 are affixed to the end panels 68 and 70 when the tray 14 is formed. It will be appreciated that at least the bottom panel 62 of the tray 14 can include an insulative material for creating an insulating barrier between food items in a lower compartment 96 defined within the carton 12 and food items in an upper compartment 98 defined within the tray 14.

The tray 14 is adapted for being disposed at least partially or fully in an interior of the carton 12. As best illustrated in FIG. 2, the tray 14 may be suspended, hung or otherwise positioned in the carton 12. In one embodiment, the tray 14 is suspended within an upper portion of the carton 12. As illustrated in the figures, the tray 14 includes generally opposing tabs 100 and 102 extending upwardly and/or outwardly from the tray's end panels 68 and 70 suitable for becoming removably retained in and engaged with generally opposing notches 104 and 106 defined in the end panels 22 and 24 of the carton 12. The tabs 100 and 102 may formed within the peripheral bounds of the tray's end panels 68 and 70 and may be formed by cuts or recesses 108, 110, 112 and 114 defined in the panels 68 and 70. Alternatively, the tabs 100 and 102 may extend beyond the distal edges 116 and 118 of the tray's end panels 68 and 70.

The tabs 100 and 102 may include one or more extending projections 120, 122, 124 or 126 suitable for engaging the end panels 22 and 24 of the carton 12 to prevent the tray 14 from sinking or dropping into the lower compartment 96, especially when the tray 14 is loaded with a relatively dense or heavy food item. As seen in the figures, the tabs 100 and 102 each have forwardly extending projections 120 and 124 and generally opposing rearwardly extending projections 122 and 126. Each projection 120, 122, 124 and 126 may be in the form of an ear, hook, lug, protrusion, protuberance, extension or other projecting member suitable for engaging the end panels 22 and 24 of the carton 12 adjacent the notches 104 and 106. The tabs 100 and 102 are optionally connected to the tray's end panels 68 and 70 via score lines or fold lines 136 and 138. Accordingly, as best depicted in FIG. 2, the tabs 100 and 102 may be folded outwardly in order to assist in supporting the tray 14 in its suspended position within the carton 12.

Each notch 104 and 106 may be in the form of a cut, cut-out, slot, slit, hole, opening or aperture defined through the carton end panels 22 and 24. The notches 104 and 106 may each have an open upper end adapted for receiving the tabs 100 and 102 of the tray 14 therethrough. The notches 104 and 106 may include one or more projections 128, 130, 132 or 134 that extend inwardly into the notches 104 and 106 in order to prevent the tray's tabs 100 and 102 from becoming inadvertently upwardly disengaged or lifted from the notches 104 and 106. However, it will be appreciated that the projections 128, 130, 132 and 134 may be deflected by a user to allow the tabs to become selectively disengaged from the notches 104 and 106. As seen in the figures, each notch 104 and 106 includes a reardwardly extending projection 128 and 132 and a forwardly extending projection 130 and 134 extending therein. Each projection 128, 130, 132 and 134 may be in the form of an ear, hook, lug, protrusion, protuberance, extension or other projecting member suitable for engaging and preventing the tray's tabs 100 and 102 from being inadvertently disengaged or lifted out of the notches 104 and 106.

It will be appreciated that the tabs 100 and 102 and notches 104 and 106 may be arranged in any suitable configuration. For example, the notches 104 and 106 may be defined in, and the tabs 100 and 102 may extend from, panels other than those illustrated in the figures. In other embodiments, notches may be defined within the tray and tabs may extend from the carton. It will further be appreciated that the assembly 10 may optionally include one of more additional trays (not shown) that are configured for extending below or beside the first tray 14 shown in the accompanying figures.

In one embodiment, the primary function of the container assembly 10 of the present invention is to hold two or more different food items in a separated fashion. The assembly 10 may be adapted for holding multiple food items in a spaced apart configuration. In one example, a side order (e.g., fries or chips) may be placed in the upper compartment 98 and a main entrée (e.g., sandwich or burger) may be placed in the lower compartment 96. In another example, a warm food item (e.g., brownie) may be placed in the upper compartment 98 and a cold food item (e.g., ice cream) may be placed in the lower compartment 96. The container assembly 10 of the present invention allows the different food items to be stored separate from one another until serving. The food items may be combined (e.g., brownie a la mode) and served in the tray 14, which may further function as a bowl or plate in this instance. In one embodiment, the tray 14 is constructed of a material suitable, not only for serving, but also for reheating and baking as well. Further, an insulating air gap may be provided between the lower food item (e.g., ice cream) and the bottom panel 62 of the tray 14. The notches 104 and 106 may serve to vent the tray 14 and the carton 12. Notwithstanding the foregoing, it will be understood that the container assembly 10 of the present invention is also suitable for containing non-food items as well.

The carton 12 and tray 14 may each be constructed from a flat sheet or blank of material that is die cut from a larger sheet or roll of material (not shown). Score lines and/or fold lines may be stamped, rolled, embossed or otherwise formed in the blanks to facilitate formation of the carton and tray in a folding process. It will be appreciated that one or both of the carton 12 and tray 14 may be formed of an insulating multi-walled construction or may further include an insulating material (not shown) surrounding at least a portion thereof. This may be especially beneficial when warm or cold food items are stored within the assembly 10. FIG. 4 illustrates a blank 140 from which the carton 12 may be formed and FIG. 5 illustrates a blank 142 from which the tray 14 may be formed.

From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. 

What is claimed is:
 1. A container assembly for containing at least two articles generally arranged one above the other, said container assembly comprising: a carton including a carton sidewall extending generally upwardly from a carton bottom panel defining an interior of said carton, said carton sidewall having first and second generally opposing notches defined therein; and a tray disposed at least partially in the interior of said carton, said tray including first and second generally opposing tabs for engaging said first and second notches of said carton for suspending said tray within the interior of said carton.
 2. The container assembly of claim 1 further comprising a first compartment defined in a lower portion of said carton and a second compartment defined within said tray.
 3. The container assembly of claim 1, wherein said carton sidewall is formed from at least a carton front panel, a carton rear panel, a carton first end panel and a carton second end panel, and wherein said first notch is at least partially defined in said carton first end panel and said second notch is at least partially defined in said carton second end panel.
 4. The container assembly of claim 3 further comprising a cover panel hingedly connected to said carton rear panel.
 5. The container assembly of claim 1, wherein said tray is formed from at least a tray bottom panel, a tray front panel, a tray rear panel, a tray first end panel and a tray second end panel, and wherein said first tab extends from said tray first end panel and said second tab extends from said tray second end panel.
 6. The container assembly of claim 1, wherein the first and second tabs of said tray each include at least one holding projection extending therefrom for engaging a portion of said carton sidewall adjacent a respective said notch.
 7. The container assembly of claim 1, wherein the first and second tabs of said tray each include first and second generally opposing holding projections extending therefrom for engaging a portion of said carton sidewall adjacent a respective said notch.
 8. The container assembly of claim 1, wherein said first and second notches each comprise at least one retaining projection extending therein for retaining a respective tab therein.
 9. The container assembly of claim 8, wherein said first and second notches each include at least two generally opposing retaining projections extending therein for retaining a respective tab therein.
 10. The container assembly of claim 1, wherein said carton and said tray are each constructed of a paperboard material.
 11. A container assembly for containing at least two articles generally arranged one above the other, said container assembly comprising: a carton including a carton bottom panel, a carton front panel, a carton rear panel, a carton first end panel and a carton second end panel; a first notch at least partially defined in said carton first end panel, said first notch including a first retaining projection extending therein; a second notch at least partially defined in said carton second end panel, said second notch including a second retaining projection extending therein; a tray disposed at least partially in an upper section of said carton, said tray including a tray bottom panel, a tray front panel, a tray rear panel, a tray first end panel and a tray second end panel; a first tab extending from said tray first end panel, said first tab adapted for being removably retained within said first notch, wherein said first tab includes a first holding projection extending therefrom for engaging a portion of said carton first end panel adjacent said first notch; and a second tab extending from said tray second end panel, said second tab adapted for being removably retained within said second notch, wherein said second tab includes a second holding projection extending therefrom for engaging a portion of said carton second end panel adjacent said second notch.
 12. The container assembly of claim 11 further comprising a first compartment defined in a lower region of said carton and a second compartment defined within said tray.
 13. In combination, a foldable carton blank and a foldable tray blank for forming a container assembly for containing at least two articles generally arranged one above the other, the carton blank comprising: a carton bottom panel; a carton front panel foldably connected to said carton bottom panel; a carton rear panel foldably connected to said carton bottom panel; a carton first end panel foldably connected to said carton bottom panel, said carton first end panel having a first notch defined therein; a carton second end panel foldably connected to said carton bottom panel, said carton second end panel having a second notch defined therein; the tray blank comprising: a tray bottom panel; a tray front panel foldably connected to said tray bottom panel; a tray rear panel foldably connected to said tray bottom panel; a tray first end panel foldably connected to said tray bottom panel, said tray first end panel including a first tab extending therefrom and further including a first holding projection extending from said first tab; a tray second end panel foldably connected to said tray bottom panel, said tray second end panel including a second tab extending therefrom and further including a second holding projection extending from said second tab.
 14. The combination of claim 13, wherein said first notch is defined proximate a distal end of said carton first end panel and said second notch is defined proximate a distal end of said carton second end panel
 15. The combination of claim 13, wherein said first tab extends proximate a distal end of said first tray first end panel and said second tab extends proximate a distal end of said second tray first end panel.
 16. The combination of claim 13 further comprising a first retaining projection extending into said first notch and a second retaining projection extending into said second notch.
 17. The combination of claim 13, wherein said first holding projection is adapted for engaging a portion of said carton first end panel adjacent said first notch and said second holding projection is adapted for engaging a portion of said carton second end panel adjacent said second notch when said carton blank is formed into a carton and said tray blank is formed into a tray. 